Thermal packing container

Abstract

A thermal packing container that includes a plurality of walls formed from a single composite individual sheet. The composite sheet includes a corrugated substrate, a metalized barrier and an outer foam layer. The composite sheet can be transported in flat configuration and then formed into a container at a packing facility. The packing container is relatively impervious to fluids and has a high thermal impedance that minimizes heat flow into the contents of the container. The thermal packing container can be used to transport food items from the packing facility.

1 . A thermal packing container, comprising:
 a plurality of walls formed from a single composite individual sheet that includes a corrugated substrate, a metalized barrier and an outer foam layer.   
     
     
         2 . The thermal packing container of  claim 1 , wherein said metalized barrier is laminated to said corrugated substrate with an adhesive. 
     
     
         3 . The thermal packing container of  claim 1 , wherein said outer foam layer is laminated to said metalized barrier with an adhesive. 
     
     
         4 . The thermal packing container of  claim 1 , wherein said corrugated substrate includes a pair of corrugated liners attached to a corrugated medium. 
     
     
         5 . A composite sheet used to form a thermal packing container, comprising:
 a corrugated substrate;   a metalized barrier attached to said corrugated substrate; and,   an outer foam layer attached to said metalized barrier.   
     
     
         6 . The wall of  claim 5 , wherein said metalized barrier is laminated to said corrugated substrate with an adhesive. 
     
     
         7 . The wall of  claim 5 , wherein said outer foam layer is laminated to said metalized barrier with an adhesive. 
     
     
         8 . The wall of  claim 5 , wherein said corrugated substrate includes a pair of corrugated liners attached to a corrugated medium. 
     
     
         9 . A process for creating a thermal packing container, comprising:
 forming a composite sheet that includes a corrugated substrate, a metalized barrier and an outer foam layer;   cutting the composite sheet into a plurality of single composite individual sheets at a first facility;   transporting the plurality of single composite individual sheets to a second facility; and,   forming a plurality of thermal packing containers from the single composite individual sheets at the second facility.   
     
     
         10 . The method of  claim 9 , wherein the composite sheet is formed by laminating the metalized barrier to the corrugated substrate and laminating the outer foam layer to the metalized barrier. 
     
     
         11 . The method of  claim 9 , wherein the composite sheet is cut with a die cutting machine. 
     
     
         12 . The method of  claim 9 , wherein the individual pieces are transported in a stacked arrangement.